Multi-channel imaging engine apparatus

ABSTRACT

A multi channel video engine ( 10 ) for accepting, dividing, modifying and recombining light to project an image. A housing ( 12 ) encloses an optical assembly ( 28 ) having a dichroic mirror assembly ( 58 ) and a color cube ( 60 ). A plurality of LCD assemblies ( 30 ) accept light from the dichroic mirror assembly ( 58 ), modifies it, and reflects it to the color cube ( 60 ). A lens assembly ( 16 ) is affixed to a bulkhead ( 24 ) of the housing ( 12 ) using a lens cradle ( 14 ) and lens retainer ( 18 ). An output prism ( 54 ) aligns light onto a second plane ( 70 ) to coincide with an optical axis ( 72 ) of the lens assembly ( 16 ).

TECHNICAL FIELD

The present invention relates to the field of multi channel imaging devices, and more particularly to projection type imaging devices, wherein it is very important to accurately align physical components of the apparatus such that the color components of a resulting image will be aligned. The predominant current usage of the present inventive multi channel imaging engine is as a component of projection video display devices, wherein it is desirable to have a rugged and accurately aligned electro-optical unit for projecting well aligned color images therefrom.

BACKGROUND ART

The typical arrangement for multi-channel imaging systems will have a clamshell arrangement where the internal optics and components are assembled from above and the optical cavity is split along a horizontal plane into two halves. However, the construction of such a device results in two or more assembly planes. For example, at least one is horizontal for the placement of the splitting and combining optics, and at least one is vertical for the placement of the projection optics. This requires complex molded parts with expensive tooling. Since there are two or more assembly planes, the registration of the optics becomes more difficult. This problem is made worse in an off-axis design where the optics are not all on the same plane.

It would be desirable to have a multi-channel imaging system wherein the alignment problems discussed above are ameliorated. It would be of further benefit if such a device were sufficiently rigid to prevent distortion problems caused by flexing and vibration. However, such a solution, in order to be practical, should be inexpensive to produce and inexpensive to use in the production of a final multi channel image projection system.

To the inventor's knowledge, all previous apparatus or methods for producing a multi channel imaging engine have been difficult and/or expensive to manufacture and assemble, less than optimally rigid, and difficult to align and use.

DISCLOSURE OF INVENTION

Accordingly, it is an object of the present invention to provide a video projection engine that will provide sub-pixel accuracy over an entire image range.

It is still another object of the present invention to provide a video projection engine which is simple to construct and wherein components are readily aligned.

It is yet another object of the present invention to provide a video projection engine wherein there are no problems of mis-convergence due to twisting or bending of the optical housing.

It is still another object of the present invention to provide a video projection engine wherein artifacts from vibration introduced from external sources is minimized.

It is yet another object of the present invention to provide a video projection engine which is inexpensive to produce.

It is still another object of the present invention to provide a video projection engine which can be used with inexpensive auxiliary components.

It is yet another object of the present invention to provide a video projection engine which is inexpensive to install and align.

Briefly, an embodiment of the present invention is an assembly of mechanical components that aligns, supports and houses the optical, opto-mechanical and electronic components of a three color projection system. The architecture is executed in such a way that it solves many of the problems that are associated with high resolution multi-channel imaging systems. The total cost of the components is reduced because the number of components is less and the parts can be manufactured with high volume, low cost processes. The inter-channel stiffness and the mechanical stability between the individual color channels is superior to previous approaches. This is a direct consequence of the novel approach for enclosing the multi-channel cavity. There is no optical alignment required other than convergence of the discreet images. The components are all self-aligning with very low cost registration features.

The invention has a housing that is constructed in such a way that the entire optical cavity is contained inside the single formed part. The cavity is enclosed with a bulkhead that serves as a frame to align and support the optics and opto-mechanics. There is only a single assembly plane that is the plane of the bulkhead. The splitter and combiner optics are attached to the bulkhead as well as the projection lens. The cavity is enclosed when the kernel housing is attached to the bulkhead. The kernel housing can be formed as a single piece and there are no secondary operations required. The bulkhead can be stamped or molded and the bracket that holds the splitter dichroics, the combiner prism, the polarizer/analyzer assembly, and/or any additional optical devices can be molded (also with no secondary operations). There is a novel focussing mount for the projection lens that allows for a simple, low cost, fixed focus lens.

An advantage of the present invention is that a relatively inexpensive video projection engine is provided for incorporation into video projection imaging devices.

A further advantage of the present invention is that sub-pixel accuracy is provided over an entire image.

Yet another advantage of the present invention is that effects of vibration are essentially eliminated, such that cooling fans can be mounted on the video projection engine without adverse effects.

Still another advantage of the present invention is that the rigidity of the video projection engine essentially eliminates problems of mis-convergence due to twisting or bending of the optical housing.

Yet another advantage of the present invention is that the video projection engine is rugged in construction and reliable in operation.

Still another advantage of the present invention is that it is inexpensive to produce.

Yet another advantage of the present invention is that it is inexpensive to install, align, and use.

These and other objects and advantages of the present invention will become clear to those skilled in the art in view of the description of modes of carrying out the invention, and the industrial applicability thereof, as described herein and as illustrated in the several figures of the drawing. The objects and advantages listed are not an exhaustive list of all possible advantages of the invention. Moreover, it will be possible to practice the invention even where one or more of the intended objects and/or advantages might be absent or not required in the application.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of a multi channel imaging engine according to the present invention;

FIG. 2 is an exploded perspective view of the multi channel imaging engine of FIG. 1;

FIG. 3 is an exploded perspective view of the lens unit of FIGS. 1 and 2;

FIG. 4 is an exploded perspective view of the bulkhead and the optical assembly of FIGS. 1 and 2;

FIG. 5 is an exploded perspective view of the optical assembly of FIGS. 1, 2 and 4;

FIG. 6 is a perspective view of another embodiment of a multi channel imaging engine according to the present invention; and

FIG. 7 is an exploded perspective view of the example of the multi channel imaging engine of FIG. 6.

DETAILED DESCRIPTION OF THE INVENTION

The embodiments and variations of the invention described herein, and/or shown in the drawings, are presented by way of example only and are not limiting as to the scope of the invention. Unless otherwise specifically stated, individual aspects and components of the invention may be omitted or modified, or may have substituted therefore known equivalents, or as yet unknown substitutes such as may be developed in the future or such as may be found to be acceptable substitutes in the future. The invention may also be modified for a variety of applications while remaining within the spirit and scope of the claimed invention, since the range of potential applications is great, and since it is intended that the present invention be adaptable to many such variations.

The mode for carrying out the invention, as described herein, is a multi channel imaging engine. An example of the inventive multi channel imaging engine is depicted in a perspective view in FIG. 1 and is designated therein by the general reference character 10. The multi channel imaging engine 10 has a housing 12 with a lens cradle 14 affixed thereto. The lens cradle 14 supports a lens assembly 16 which is held in place, thereon, by a lens retainer 18. The assembled lens cradle 14, lens assembly 16, and lens retainer 18 will be referred to, herein, as a lens unit 19.

This example of the invention has two cooling fans 20 affixed to the housing 12. While the cooling fans 20 are not a necessary part of the invention, it is instructive to note that the present inventive multi channel imaging engine 20 is sufficiently rigid that the cooling fans 20 can be mounted thereon without the adverse effects of vibration which would result from a less rigid device.

In this embodiment of the invention, the housing 12 has a kernel housing 22 and a bulkhead 24. The kernel housing 22 described herein is die cast from aluminum alloy, although other construction techniques including but not limited to alternative molding methods are within the scope of the invention. Another example of a construction technique would be to press form the housing from a single piece of sheet steel, or to cut and bend sheet metal into the desired shape. The bulkhead 24 is affixed to the kernel housing 22 by screws 26, as shown by way of example in the view of FIG. 1 such that an interior 27 of the housing 12 is generally enclosed by the bulkhead 24 and the kernel housing 22.

An optical assembly 28 is affixed to the bulkhead 24 within the housing 12, and three LCD assemblies 30 are affixed to the outside of the housing 12. The LCD assemblies 30 may optionally be of essentially any reflective type, wherein light projected onto one of the LCD assemblies 30 is modified according to an image electronically provided to the LCD assembly and the light, modified to conform to the image, is reflected therefrom. One skilled in the art will be familiar with such devices. In this present embodiment of the multi channel imaging engine 10, the LCD assemblies 30 are of the commercially available type. The LCD assemblies 30 are each affixed to the kernel housing 22 using an alignment mount 32 whereby the LCD assemblies 30 may be aligned, as necessary, during final assembly of the multichannel imaging engine 10. One skilled in the art will also be familiar with the alignment mount 32, and variations of such that are available.

FIG. 2 is an exploded perspective view of a portion of the multichannel imaging engine 10 of FIG. 1. In the view of FIG. 2, it can be seen that the optical assembly 28 is affixed to the bulkhead 24. Also, in the view of FIG. 2 it can be seen that the lens cradle 14 has an additional plurality (three are visible in the view of FIG. 2) of the screws 26 for affixing the lens cradle 14 to the bulkhead 24.

A light entry port 34 can be seen in the bulkhead 24 wherethrough white light is introduced into the housing 12. Also visible in the view of FIG. 2 are two of the three LCD ports 36 wherethrough light is projected onto, and reflected form the LCD assemblies 30 (FIG. 1). One of the two cooling ports 38 of this embodiment of the invention, whereon the cooling fans 20 (FIG. 1) are affixed, is also visible in the view of FIG. 2.

FIG. 3 is an exploded perspective view of the lens unit 19, previously discussed herein in relation to FIGS. 1 and 2. The fixed focus lens assembly 16 has a positioning projection 40, and the lens cradle 14 has two retaining rings 42 for accepting the lens assembly 16. Each of the retaining rings 42 has a gap 44 therein such that the lens assembly can be inserted into the lens cradle 14 with the positioning projection 40 aligned with the gaps 44. The lens assembly 16 is then secured in position in the lens cradle 14 by the lens retainer 18 using a pair of cap screws 46. As can be seen in the view of FIG. 3, a positioning slot 48 in the lens retainer 18 is angled such that, when the positioning projection 40 is within the positioning slot 48, the rotating the lens assembly 16 (with the cap screws 46 appropriately loosened), as indicated by arrow 50, will cause the fixed focus lens assembly 16 to move forward or backward in the lens cradle 14, as indicated by arrow 52, such that the lens assembly 16 can be focused, as required.

FIG. 4 is an exploded view of the bulkhead 14 and optical assembly 28 wherein the optical assembly 28 can be more readily viewed. As can be seen in the view of FIG. 2, an output truncated doublet 54 (which is effectively used as a prism for redirecting light) of the optical assembly 28 projects partially through a light exit port 56 in the bulkhead 14 when the optical assembly 28 is affixed to the bulkhead 14. Also visible in the view of FIG. 4 are a dichroic mirror assembly 58, and a color cube 60, which will be discussed in more detail, hereinafter. The output truncated doublet 54, the dichroic mirror assembly 58 and the color cube 60 are each affixed to an optical frame 62.

FIG. 5 is an exploded perspective view of the optical assembly 28, according to this presently described embodiment of the invention. One skilled in the art will recognize that the dichroic mirror assembly 58 has three dichroic mirrors 64 arranged in an “X” configuration such that white light projected onto the dichroic mirror assembly 58 is divided into its three basic component wavelength colors, with one of each such colors being directed toward a corresponding one of the LCD assemblies 30 (FIG. 1). One skilled in the art will also recognize that the color cube 60 is made up of four color cube prisms 65 with the contiguous surfaces thereof having dichroic surfacing such that three primary color light beams reflected from the three LCD assemblies 30 are recombined and directed toward the output truncated doublet 54.

It is important to note that, in this embodiment of the invention, light us directed slightly upward (from a perspective where the color cube 60 is above the dichroic mirror assembly 58) as light enters the housing 12 through the light entry port 34 (FIG. 2), as indicted by a light input path arrow 66 in FIG. 1. Accordingly, as light travels through the multi channel imaging engine 10, the light is divided by the dichroic mirror assembly 58, modified by and reflected from the LCD assemblies 30, and recombined by the color cube 60 relative to a first plane 68. The light is also moving relative to a second plane 70 (generally upward, as discussed previously herein) such that the light first passes through the dichroic mirror assembly 58, is then reflected at an upward angle from the LCD assemblies 30, and then passes through, and is recombined by, the color cube 60. Since an optical axis 72 of the lens assembly 16 is aligned generally along the first plane 68, the output truncated doublet 54 is shaped and configured to realign the (slightly upward canted) light with the optical axis 72 of the lens assembly 16.

Accordingly, the described embodiment of the multi channel imaging engine 10 is assembled generally as follows: The optical assembly 28 is assembled as described herein and affixed to the bulkhead 24. The bulkhead is affixed to the kernel housing 22 generally enclosing the interior 27 thereof. The LCD assemblies 30 are affixed to the exterior of the kernel housing 22, using the alignment mounts 32, as previously described herein. Except as otherwise stated, or as may be necessitated by a particular application or variation of the invention, the order of assembly operations is not critical and is not an inherent part of the invention.

Another embodiment of the multi channel imaging engine is depicted in a perspective view in FIG. 6 and is designated therein by the general reference character 10 a. This embodiment of the multi channel imaging engine 10 a is not greatly different in kind and in components from the previously described multi channel imaging engine 10, previously described herein. The multi channel imaging engine 10 a is presented here in order to illustrate some possible variations in shape and construction as described herein and as depicted in the drawings. As can be seen in the view of FIG. 6, the multi channel imaging engine 10 a has a housing 12 a with a lens cradle 14 a affixed thereto. The lens cradle 14 a supports a lens assembly 16 a which is held in place, thereon, by a lens retainer 18 a. The assembled lens cradle 14 a, lens assembly 16 a, and lens retainer 18 a will be referred to, herein, as a lens unit 19 a. As can be seen in the view of FIG. 6, two of the cooling fans 20 are affixed to the housing 12 a in this embodiment of the invention, as well.

In this embodiment of the invention, also, the housing 12 a has a kernel housing 22 a and a bulkhead 24 a, each of which are constructed by methods similar to those previously described in relation to the first described embodiment of the invention, herein, and shaped as shown in the view of FIG. 6 and the subsequent figures of the drawing.

An optical assembly 28 a is affixed to the bulkhead 24 a within the housing 12 a, and three LCD assemblies 30, which are not significantly different from the LCD assemblies 30 previously described herein, are affixed to the outside of the housing 12 a.

FIG. 7 is an exploded perspective view of a portion of the multichannel imaging engine 10 a of FIG. 6. In the view of FIG. 7, it can be seen that the optical assembly 28 a is affixed to the bulkhead 24 a. Indeed, in this embodiment of the multi channel imaging engine 10, the components of the optical assembly 28 a are affixed directly to the bulkhead 24 a, as will be discussed in more detail, hereinafter. In this embodiment also, a light entry port 34 a can be seen in the bulkhead 24 a wherethrough white light is introduced into the housing 12 a. Also visible in the view of FIG. 7 are two of the three LCD ports 36 a wherethrough light is projected onto, and reflected form the LCD assemblies 30 (FIG. 6). One of two cooling ports 38 a of this embodiment of the invention, whereon the cooling fans 20 (FIG. 6) are affixed, is also visible in the view of FIG. 7. The fixed focus lens assembly 16 a, the lens cradle 14 a, and the lens retainer 18 a function much like the fixed focus lens assembly 16 and the lens cradle 14 previously discussed herein in relation to FIG. 3, although the actual shape is somewhat different, as can be seen by comparison of the views of FIGS. 2 and 7.

As can be seen in the view of FIG. 7, an output doublet 54 a is positioned in relation to a light exit port 56 a, and performs functions previously as described herein in relation to the truncated doublet 54 of the previously described embodiment.

In this presently described embodiment 10 a of the present invention, the dichroic mirrors 64 are assembled within a mirror receptacle 74 which is formed as a part of the bulkhead 24 a, and the color cube 60 is affixed to the bulkhead 24 a. The dichroic mirrors 64 and the color cube 60 are essentially the same as, and function in an similar manner to like elements previously discussed herein in relation to the first described embodiment 10 of the invention.

Various modifications may be made to the invention without altering its value or scope. For example, the housing 12 could be molded and/or made from another material.

All of the above are only some of the examples of available embodiments of the present invention. Those skilled in the art will readily observe that numerous other modifications and alterations may be made without departing from the spirit and scope of the invention. Accordingly, the disclosure herein is not intended as limiting and the appended claims are to be interpreted as encompassing the entire scope of the invention.

INDUSTRIAL APPLICABILITY

The inventive multi channel imaging engine 10 is intended to be widely used in the production of video image projection systems such as high resolution projection television devices, and particularly computer video output projection display devices. The invention allows convergence to sub-pixel accuracy over the entire image. The assembly is simplified by the self-aligning features and there is no alignment of optics other than the convergence of the three image channels. The inter-channel stiffness is substantially high so that there are no problems of misconvergence due to twisting or bending of the optical housing. There is a substantial cost advantage because the construction of the mechanics allows for simple molded and stamped parts with no secondary machining operations. The focussing mount can be molded and allows the projection lens to be purchased as a low cost fixed focus lens.

This mechanical architecture is a departure from the typical method of projection system assembly. It permits low cost system solutions, especially with (but not exclusive to) off-axis projection systems. This will allow off-axis reflective projection systems to complete effectively in the market for high resolution, low cost display systems.

One skilled in the art will readily understand the alignment procedures used in conjunction with the present invention. For example, the alignment mounts 32 are used to adjust the LCD assemblies such that the three color component images properly align when recombined in the color cube 60. Similarly, the lens retainer 18 will be loosened and the lens assembly rotated, as briefly discussed herein before, to properly adjust the focal aspect of the lens assembly 16.

Since the multi channel video projection engine 10 of the present invention may be readily produced and integrated with existing video creation and display systems and devices, and since the advantages as described herein are provided, it is expected that it will be readily accepted in the industry. For these and other reasons, it is expected that the utility and industrial applicability of the invention will be both significant in scope and long-lasting in duration. 

What is claimed is:
 1. A video projection engine, comprising: a bulkhead; an optical unit mounted to said bulkhead, said optical unit including a dichroic mirror assembly for dividing light and a light recombining apparatus; a housing fixed to said bulkhead, said optical unit not rigidly fastened to said housing except through said bulkhead; and a plurality of reflective display assemblies mounted on said housing for receiving the light from said dichroic mirror assembly, modifying the light, and reflecting the light toward said light recombining apparatus.
 2. The video projection engine of claim 1, wherein: said housing together with said bulkhead fully enclose said optical unit.
 3. The video projection engine of claim 1, wherein: said light recombining apparatus is a color cube.
 4. The video projection engine of claim 1, and further including: a lens assembly optically aligned to receive light from said optical unit.
 5. The video projection engine of claim 1, wherein: the lens assembly is physically affixed to said bulkhead.
 6. The video projection engine of claim 1, and further including: a prism fixed to said bulkhead for redirecting light received from said recombining apparatus into a lens assembly.
 7. The video projection engine of claim 1, and further including: a cooling fan affixed to said housing.
 8. The video projection engine of claim 1, wherein: said optical assembly is fully enclosed within said housing when said bulkhead is affixed to the housing.
 9. A video projection device for accepting light, dividing the light, modifying the light, recombining the light, and projecting the light, comprising: a housing; a bulkhead for generally enclosing space within said housing; a light admitting aperture in said bulkhead for admitting light; an optical unit generally within said housing for dividing and recombining the light; a plurality of reflective display units for modifying the light; and a light output aperture for projecting the light therethrough from within said housing.
 10. The video projection device of claim 9, and further including: a lens assembly for focusing light emitted from said light output aperture.
 11. The video projection device of claim 10, wherein: said lens assembly is affixed to said bulkhead.
 12. The video projection device of claim 9, and further including: a color dividing apparatus and a color recombining apparatus arranged along a first plane, wherein said plurality of reflective display units are arranged along a second plane.
 13. The video projection device of claim 9, and further including: a prism for receiving recombined light from said optical unit and redirecting said recombined light through said light output aperture into a lens.
 14. The video projection device of claim 13, wherein: the prism is affixed to said optical unit.
 15. A video projection engine having a first dimensional plane and a second dimensional plane, comprising: a light dividing apparatus and a light recombining apparatus arrayed on the first dimensional plane, by fixing said light dividing apparatus and said light recombining apparatus to a first structure; and a plurality of light modifying devices arrayed on said second dimensional plane, by fixing said light modifying devices to a second structure; whereby said light dividing apparatus and said light recombining apparatus are aligned with said light modifying devices by fixing said first structure to said second structure.
 16. The video projection engine of claim 15, wherein: said light dividing apparatus includes a dichroic mirror.
 17. The video projection engine of claim 15, wherein: said light recombining apparatus includes a color cube.
 18. The video projection engine of claim 15, wherein: said light modifying devices are reflective LCD units.
 19. The video projection engine of claim 15, wherein: said light dividing apparatus and said light recombining apparatus are enclosed within a housing formed by said first structure and said second structure.
 20. The video projection engine of claim 15, wherein: the first dimensional plane is generally perpendicular to the second dimensional plane.
 21. The video projection engine of claim 15, and further including: a prism for aligning light emitted from said light recombining apparatus generally in a direction parallel to said second dimensional plane.
 22. A video projection optical housing for accepting a plurality of reflective imaging devices and an optical component; comprising: a formed housing adapted to accept the imaging devices on the exterior and having a hollow interior adapted to accept the optical component therein, said formed housing defining openings to facilitate the passage of light between said optical component and said reflective imaging devices.
 23. The video projection optical housing of claim 22, and further including: a bulkhead generally enclosing the hollow interior.
 24. The video projection optical housing of claim 23, wherein: the optical component is affixed to the bulkhead.
 25. The video projection optical housing of claim 23, and further including: a lens assembly affixed to the bulkhead.
 26. The video projection optical housing of claim 22, wherein: the formed housing is a generally rigid three dimensional piece enclosing the hollow interior.
 27. The video projection optical housing of claim 22, wherein: the formed housing is die cast.
 28. The video projection optical housing of claim 22, wherein: the formed housing is press formed.
 29. The video projection optical housing of claim 22, wherein: the formed housing is made of metal.
 30. The video projection optical housing of claim 22, wherein: the formed housing is a unitary piece.
 31. The video projection optial housing of claim 22, wherein: the formed housing approximates a section of a toroid.
 32. A method for assembling a video projection imaging engine comprising: a. assembling an optical assembly; b. affixing the optical assembly to a bulkhead; c. affixing the bulkhead to a housing shell such that the bulkhead generally encloses a hollow interior of the housing shell with the optical assembly therein; and d. affixing a plurality of reflective imagers to the exterior of the housing shell.
 33. The method of claim 32, wherein: the operations a, b, c and d are accomplished in the order given.
 34. The video projection engine of claim 1, wherein: said dichroic mirror assembly includes a plurality of dichroic mirrors arranged in an “X” configuration.
 35. The video projection engine of claim 1, wherein: said optical unit is fixed directly to said bulkhead.
 36. The video projection engine of claim 1, wherein: said reflective display assemblies include reflective LCDs.
 37. The video projection engine of claim 7, wherein: said fan is affixed to the exterior of said housing.
 38. The video projection device of claim 12, wherein: said color dividing apparatus includes a plurality of dichroic mirrors arranged in an “X” configuration.
 39. The video projection engine of claim 16, wherein: said light dividing apparatus includes a plurality of dichroic mirrors arranged in an “X” configuration. 